Reel

ABSTRACT

A reel including a columnar wind-up unit  3  and a pair of opposing side plates  2  and  2  provided such that the wind-up unit is between the side plates, wherein the inner surface of at least one side plate  2  is provided with a projection  21.

This is a divisional application of U.S. patent application Ser. No.12/306,250, which was filed on Dec. 22, 2008 as the National PhaseApplication in the United States of International Patent Application No.PCT/JP2007/061964 filed Jun. 14, 2007, which claims priority on JapanesePatent Application No. 2006-170961 filed Jun. 21, 2006. The entiredisclosures of the above patent applications are hereby incorporated byreference.

TECHNICAL FIELD

The invention relates to a reel for winding an adhesive tape (a stickytape) obtained by cutting into a narrow tape a film material on which anadhesive layer (or a sticky layer) is formed.

BACKGROUND

In recent years, an anisotropic conductive film obtained byincorporating conductive fine particles into an adhesive layer formed ona substrate is widely used in circuit connection of liquid crystaldisplays. Generally, as stated in Patent Document 1 or the like, thistype of anisotropic conductive film is manufactured and supplied by amethod in which an adhesive layer is formed by coating or the like on awide film material and the resultant is cut into a narrow tape.

Patent Document 1: JP-A-2003-34468

DISCLOSURE OF THE INVENTION Problem to be Solved by the Invention

The inventors made extensive studies. As a result, the inventors havefound that, in producing an anisotropic conductive film, there is yetroom for improvement in the production method in which a film materialon which an adhesive layer is formed by coating is wound around a reelwhile cutting it into a narrow tape. Specifically, during winding arounda reel or during storage of the wound tape, an adhesive forming theadhesive layer tends to adhere to the inner surface of the reel,resulting in formation of defective products.

The invention has been made based on the above-mentioned studies by theinventors. An object of the invention, in manufacturing and supplying anadhesive film (tape) such as an anisotropic conductive film by a methodin which a film material on which an adhesive layer is formed by coatingis wound around a reel while cutting it into a narrow tape, is toprovide a reel which can prevent adherence of an adhesive to the innersurface of the reel to improve yield, as well as ensure stable unwindingof the adhesive tape for use.

Means for Solving the Problem

The reel of the invention, which solves the above-mentioned problem,comprises a columnar wind-up unit and a pair of opposing side platesprovided such that the wind-up unit is between the side plates, whereinthe inner surface of one or both of the side plates is provided with aprojection which extends continuously or intermittently.

The reel of the invention with the above-mentioned configuration has anovel shape which cannot be found in conventional reels. If adhesivetapes are manufactured and supplied by a method in which a film materialon which an adhesive layer is formed by coating is wound up around thereel of the invention while cutting it into a narrow tape, it ispossible to prevent an adhesive constituting the adhesive layer fromadhering to the inner surface of the reel during manufacturing orstorage after winding.

The reel of the invention can be configured such that theabove-mentioned projection extends in the radial direction. In thiscase, it is preferred that the reel have a configuration in which theabove-mentioned projections are provided radially.

By this configuration, adherence of an adhesive constituting theadhesive layer to the inner surface of a reel can be prevented moreconsistently.

In the reel of the invention, in order to further ensure prevention ofadherence of an adhesive to the inner surface of a reel without causingproblems, it is preferred that the above-mentioned radially-directedprojection be 0.05 to 1.00 mm in height and 0.5 to 20.0 mm in width.

The reel according to the invention may have a configuration in which aperipheral projection extending in the circumferential direction thereofis provided on the inner surface along the peripheral part of one orboth of the above-mentioned side plates.

Due to such a configuration, when the adhesive tape is wound whilepreventing un-uniform winding by guiding the side surface of theadhesive tape, which is the object being wound, with the peripheral partof the side plate, it is possible to reduce the area of the adhesivetape in contact with the peripheral part, whereby adherence of theadhesive to the peripheral part of the side plate can be prevented.

In the reel of the invention, in order to reduce the area of theadhesive tape in contact with the peripheral part, which is the objectbeing wound, when winding the adhesive tape while guiding the sidesurface thereof with the peripheral part of the side plate, it ispreferred that at least part of the peripheral projection which is incontact with the object be circular in shape.

In the reel of the invention, in order to further ensure prevention ofadherence of an adhesive to the peripheral part of the side plates, itis preferred that the projection be 0.05 to 1.00 mm in height and 0.5 to20.0 mm in width.

In the reel of the invention, the object being wound can be providedwith an adhesive layer or a sticky layer. The reel of the invention canpreferably be applied to the object being wound, which is provided witha sticky layer formed by applying a material generally known as a“sticky adhesive”, and thus adherence of a sticky adhesive can beprevented.

ADVANTAGEOUS EFFECTS OF THE INVENTION

According to the invention, when winding a film material on which anadhesive layer or a sticky layer is formed by coating around a reelwhile cutting it into a narrow tape, or during storage of the woundtape, it is possible to prevent adherence of an adhesive or stickyadhesive to the inner surface of the reel, thereby improving yield byeliminating formation of defective products.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view illustrating an embodiment of the reel of theinvention;

FIG. 2 is an end view taken along the line B-B of FIG. 1( b);

FIG. 3 is an end view taken along the line C-C of FIG. 1( b);

FIG. 4 is an explanatory view showing the winding state of the adhesivetape;

FIG. 5 is a conceptual view showing the position of the projection onthe inner surface of the side plate according to a modification exampleof the reel of the invention;

FIG. 6 is an explanatory view showing the outline of the cross sectionof the projection provided on the inner surface of the side plate or theperipheral projection provided on the inner surface along the peripheralpart of the side plate according to a modification example of the reelof the invention;

FIG. 7 is a conceptual view showing the position of the peripheralprojection provided on the inner surface along the peripheral part ofthe side plate according to a modification example of the reel of theinvention;

FIG. 8 is a conceptual view showing the positions of the projectionsprovided on the inner surface of the side plate and the peripheralprojections provided on the inner surface along the peripheral part ofthe side plate according to a modification example of the reel of theinvention; and

FIG. 9 is a cross-sectional view of the part E of the adhesive tape, asshown in FIG. 4 (b).

BEST MODE FOR CARRYING OUT THE INVENTION

The preferred embodiments of the invention will be described withreference to the drawings.

FIG. 1 is an explanatory view showing the outline of the reel accordingto the invention, in which FIG. 1( a) is a front view and FIG. 1( b) isa cross sectional view of FIG. 1( a) taken along the line A-A in FIG. 1(a).

A reel 1 shown in FIG. 1 is provided with a columnar wind-up unit 3 anda pair of side plates 2 and 2 provided in parallel with or substantiallyin parallel with each other such that a wind-up unit 3 is between theside plates. A D-shaped shaft hole 4 penetrates through almost thecenter of the reel 1. By inserting the wind-up shaft of a wind-upapparatus (not shown) into this shaft hole 4, the reel 1 is installed onthis wind-up apparatus, and the reel is allowed to rotate when thewind-up shaft is driven.

The reel 1 with such a configuration is used for manufacturing andsupplying various adhesive tapes 5 by a method in which a film materialon which an adhesive layer is formed by coating as shown in FIG. 9 iscut into a narrow tape and the narrow tape is wound around the reel. Thewidth of the wind-up unit 3, namely the distance between the side plates2 and 2 which are separated by the wind-up unit 3 can be appropriatelyset according to the cut width of an adhesive tape 5 as the object beingwound. In addition, the side plate 2 is normally formed in a circularshape, and the diameter thereof can be appropriately set according tothe winding length of the adhesive tape 5.

In this embodiment, the reel 1 may be a reel which is integrally formedby injection molding or the like. However, the pair of the side plates 2and 2 and the wind-up unit 3 may be formed separately, and these partsmay be connected by an appropriate means such as fitting and adhesion.By forming the side plates 2 and 2 and the wind-up unit 3 separately,the following configuration can be realized. For example, the sideplates 2 differing in diameter can be combined with the common wind-upunit 3, thereby allowing the reel 1 to correspond to various windinglengths, or the wind-up units 3 differing in width can be combined withthe common side plate 2, thereby allowing the reel to correspond tovarious cutting widths.

In this embodiment, as shown in FIG. 1 (b) and FIG. 2, a projection 21extending in the radial direction is provided on the inner surface ofthe side plates 2 and 2.

FIG. 2 is an end view taken along the line B-B in FIG. 1( b).

The projection 21 provided on the inner surface of the side plate 2serves to avoid contact of the adhesive layer exposed on the sidesurface of an adhesive tape 4 with the inner surface of the reel 1(inner surface of the side plate 2) when winding up the adhesive tape 5around the reel 1 or during the storage of the wound adhesive tape 5,whereby the adhesive constituting the adhesive layer is prevented fromadhering to the inner surface of the reel 1.

That is, the distance between the side plates 2 and 2, which areseparated by the wind-up unit 3, is set to be larger to some extent thanthe cut width of the adhesive tape 5 such that the adhesive tape 5 to bewound around the wind-up unit 3 is prevented from being adhered to theinner surface of the side plate 2. Even with this distance, if thewinding position of the adhesive tape 5 is shifted due to irregularrotation or the like of the reel 1 during winding of the adhesive tape5, or the position of the adhesive tape 5 which has been wound isshifted due to impact or vibration during storage, the adhesive tape 5may come in contact with the inner surface of the side plate 2.

In this embodiment, even in such a case, by providing a projection 21 onthe inner surface of the side plate 2, the contact area of the adhesivelayer exposed on the side surface of the adhesive tape 5 and the innersurface of the side plate 2 can be reduced, whereby adherence of theadhesive constituting the adhesive layer to the inner surface of thereel 1 can be prevented.

In this embodiment, when such projection 21 is provided, the height h1of the projection 21 is preferably 0.05 to 1.00 mm, more preferably 0.05to 0.30 mm, and particularly preferably 0.05 to 0.20 mm.

If the height h1 of the projection 21 is less than 0.05 mm, it may behard to obtain the effects of suppressing contact of the adhesive tape 5with the inner surface of the side plate 2. In addition, the height h1of less than 0.05 mm is not preferable, since the injection moldingconditions of the reel 1 are required to be controlled accurately. Onthe other hand, if the height hl of the projection 21 exceeds 1.00 mm,the projection 21 becomes excessively high, affecting the widthdimensions of the reel 1. In addition, this height is not preferablesince pushing pressure to the side surface of the adhesive tape 5increases, and as a result, the side surface of the adhesive tape 5 mayacquire marks from the projection 21.

The width w1 of the projection 21 is preferably 0.5 to 20.0 mm, morepreferably 0.5 to 10.0 mm, and particularly preferably 0.5 to 5.0 mm.

If the width w1 of the projections 21 is less than 0.5 mm, the sidesurface of the adhesive tape 5 may become damaged. In addition, thewidth w1 of the projection 21 of less than 0.5 mm is not preferablesince the injection molding conditions of the reel 1 are required to becontrolled accurately. On the other hand, when the width w1 of theprojection 21 exceeds 20.0 mm, the adhesive may adhere to the projection21.

In this embodiment, as shown in FIG. 1, radial provision of a pluralityof (8 in the shown example) projections 21 which extend in the radialdirection is preferable, since adherence of the adhesive constitutingthe adhesive layer to the inner surface of the reel 1 can be preventedmore surely.

In this embodiment, on the inner surface along the peripheral part ofthe side plate 2, the peripheral projection 22 extending in thecircumference direction are provided as shown in FIG. 1( b) and FIG. 3.

FIG. 3 is an end view showing the cross section taken along the line C-Cin FIG. 1( b).

When winding the adhesive tape 5 around the reel 1, which has been cutto have a narrow width, as shown in FIG. 4( a), if the adhesive tape 5is slightly tilted and the side surface of the adhesive tape 5 is guidedby the peripheral part of the side plate 2, the adhesive tape 5 can bewound uniformly with flushed stacked side surfaces of the wound adhesivetape 5.

FIG. 4 is an explanatory view showing the winding-up state of theadhesive tape 5. FIG. 4( b) is a left side view of the state shown inFIG. 4( a). In this figure, the adhesive tape 5 is wound around the reel1 which rotates in the direction shown by the arrow.

In this embodiment, the peripheral projection 22 provided on the innersurface along the peripheral part of the side plate 2 serves to preventadherence of the adhesive constituting the adhesive layer to theperipheral part of the side plate 2, which is caused by the contact ofthe adhesive layer exposed on the side surface of the adhesive tape 5with the peripheral part of the side plate 2 when winding the adhesivetape 5 around the reel 1 as mentioned above.

That is, in this embodiment, when guiding the side surface of theadhesive tape 5 with the peripheral part of the side plate 2, in orderto reduce the contact area with the adhesive tape 5, the peripheralprojection 22 extending in the circumference direction is provided onthe inner surface along the peripheral part of the side plate 2 tosuppress the adhesion of the adhesive.

Therefore, it is preferred that at least part of the peripheralprojection 22 which is in contact with the adhesive tape 5 have acircular shape. The radius of curvature thereof is preferably 0.3 to 1.5mm, more preferably 0.5 to 1.0 mm in order to reduce the contact area ofthe peripheral projection 21 with the adhesive tape 5.

In this embodiment, in providing such peripheral projection 22, theheight h2 of the peripheral projection 22 is preferably 0.05 to 1.00 mm,more preferably 0.05 to 0.30 mm, and particularly preferably 0.05 to0.20 mm.

If the height h2 of the peripheral projection 22 is less than 0.05 mm,the effects of suppressing contact of the adhesive tape 5 with the innersurface of the side plate 2 are impaired. In addition, such a smallheight of the peripheral projection 22 is not preferable since theadhesive tape 5 may become scratched due to interference of theprojection 21 and the adhesive tape 5 when winding the adhesive tape 5.If the height h2 of the peripheral projection 22 exceeds 1.00 mm, theperipheral projection 22 becomes excessively high, and as a result, theperipheral projection 22 may interfere with the adhesive tape 5 whenwinding up the adhesive tape 5. In addition, since the gap between thewound adhesive tape 5 and the side plates 2 and 2 increases afterwinding of the adhesive tape 5 is completed, weaving may occur duringstorage, resulting in lowered storage stability.

The width w2 of the peripheral projection 22 is preferably 0.5 to 20.0mm, more preferably 0.5 to 10.0 mm, and particularly preferably 0.5 to5.0 mm.

If the width w2 of the peripheral projection 22 is less than 0.5 mm, theside surface of the adhesive tape 5 may become scratched. If the widthw2 of the peripheral projection 22 exceeds 20.0 mm, the problem ofadherence of the adhesive to the peripheral projection 22 occurs. Inaddition, when the adhesive tape 5 which has been wound up around thereel 1 is unwound for use, the adhesive tape 5 may become caught in theperipheral projection 22.

The preferred embodiments of the invention have been describedhereinabove. The invention is not limited to the embodiments mentionedabove, and it is needless to say that various modifications are possiblewithin the scope of the invention.

For example, in the above-mentioned embodiments, both of the pair ofside plates 2 and 2 are provided with the radially-directed projection21 or the peripheral projection 22. However, if necessary, theradially-directed projection 21 and the peripheral projection 22 may beprovided on only one of the side plates 2 and 2.

That is, if the adhesive tape 5 is wound near one of the side plates 2in order to increase the distance between the other side plate 2 and theadhesive tape 5, the radially-directed projection 21 and the peripheralprojection 22 can be provided on the one side plate 2.

In the above embodiment, the shaft hole 4 in the shape of the letter Dis shown. However, the shaft hole 4 may contain a key groovecorresponding to a key provided on the winding shaft. The specificconfiguration of the shaft hole 4 can be changed corresponding to ameans for mounting the winding apparatus to the winding shaft.

In the above-mentioned embodiment, the configuration of the winding unit3 is roughly shown. The winding unit 3 may have various configurationswhich can be applied to this type of reel, for example, provision of arib for ensuring rigidity.

In the above-mentioned embodiment, the adhesive tape 5 provided with anadhesive layer as shown in FIG. 9 is used as an object to be wound.However, the reel of the invention can preferably be applied to anobject to be wound provided with a sticky layer formed by applying amaterial generally known as a “sticky adhesive,” as shown in FIG. 9.

In the above-mentioned embodiment, the projections 21 provided on theinner surface of the side plate 2 are provided as a concave line formedcontinuously from the inner perimeter to the outer perimeter of the reel1. However, as shown in FIG. 5( a), the projections 21 may be formedintermittently. Furthermore, the projections 21 may be provided from thecenter of the side plate 2 to the periphery so that they extend in theradial direction. In addition, as shown in FIG. 5( b), the projections21 may be provided such that they intersect with the radial direction,and, as shown in FIG. 5( c), the projections 21 may be provided in aspiral shape.

If the projections 21 are provided radially, the radial center thereofis preferably the same as the center of the side plate 2. However, it ispossible to allow the radial center and the center of the side plate 2to be different, if necessary. Furthermore, it is possible to form theprojections 21 in such a manner that the projections 21 extend radiallyfrom each of these different radial centers.

Furthermore, the shape of the cross section of the projection 21 is notlimited to the above-mentioned circular shape. The cross section mayhave a rectangular shape or a rectangular shape with round corners, orthe like. The cross section may have a shape as shown in FIG. 6.

As mentioned above, there are no specific limitations on specificaspects, e.g. the number or shape of the projection 21 provided on theinner surface of the side plate 2, insofar as adherence of the adhesiveto the inner surface of the reel 1 can be prevented.

As in the case of the peripheral projection 22 provided along theperipheral part of the side plate 2, various modifications are possible,as long as adherence of the adhesive can be prevented when winding isperformed while guiding the side surface of the adhesive tape 5 with theperipheral part of the side plate 2.

In the above-mentioned embodiment, the peripheral projection 22 isprovided along the entire circumference of the peripheral part of theside plate 2. However, as shown in FIG. 7( a), the peripheral projectionmay be provided intermittently along the peripheral part of the sideplate 2. In addition, as shown in FIG. 7( b), the peripheral projectionmay be provided in a spiral form, and as shown in FIG. 7( c), aplurality of (2 in the in the shown example) peripheral projections 22may be arranged in parallel to each other.

Furthermore, as shown in FIGS. 8( a) to (c), the peripheral projections22 provided intermittently may be connected with the projections 21,which is provided to avoid adherence of the adhesive to the innersurface of the reel 1.

The cross section of the peripheral projection 22 may have the sameshape as that of the projection 21. Specifically, it may have a circularshape, a rectangular shape, a rectangular shape with round corners, or ashape shown in FIG. 6.

Here, FIGS. 5, 7 and 8 are explanatory views which conceptually show thepositions of the projections 21 and 22 in the above-mentionedmodification example. FIG. 6 is an explanatory view which shows theoutline of the shape of the cross section of the projection 21 (orperipheral projection 22). FIGS. 6( d) and (f) show two projections 21(or peripheral projections 22) which are arranged in parallel in such amanner that they are close to each other, and FIGS. 6( e) and (g) showtwo projections 21 (or peripheral projections 22) which are arranged insuch a manner that they are in contact with each other.

INDUSTRIAL APPLICABILITY

As mentioned hereinabove, the invention provides a reel used tomanufacture and supply an adhesive tape, which prevents adherence of anadhesive to the inner surface thereof.

1-11. (canceled)
 12. A method of preventing a tape having an adhesivelayer from sticking to an inner surface of a reel, the method comprisingthe steps of: (a) providing a roll of tape, including, an adhesive tape,having an adhesive layer, and a columnar wind-up unit having theadhesive tape wound thereon; (b) disposing the roll of tape between twoside plates having inner surfaces, thereby forming a reel of tape; and(c) providing the inner surfaces of one or both of the side plates witha projection extending in a radial direction, wherein the projection isdisposed to prevent the tape from adhering to the inner surfaces whenthe tape is dispensed, and wherein the projection extends continuouslyor intermittently in the radial direction.
 13. The method according toclaim 12, wherein the adhesive tape is obtained by cutting into a narrowtape an anisotropic conductive film obtained by incorporating conductiveparticles into an adhesive layer formed on a substrate.
 14. The methodto claim 12, wherein the projection is provided radially.
 15. The methodaccording to claim 12, wherein the height of the projection is 0.05 to1.00 mm.
 16. The method according to claim 12, wherein the width of theprojection is 0.5 to 20.0 mm.
 17. The method according to claim 12,wherein the reel of tape is provided with a peripheral projection alongthe periphery on the inner surface of one or both of the side plates.18. The method according to claim 17, wherein at least part of theperipheral projection which is in contact with the object being woundhas a circular shape when the adhesive tape is wound while guiding theside surface of adhesive tape by the periphery of the side plates. 19.The method according to claim 17, wherein the height of the peripheralprojection is 0.05 to 1.00 mm.
 20. The method according to claim 17,wherein the width of the peripheral projection is 0.5 to 20.0 mm.